Method of cleaning and coating sized glass fabric



Jan. 13 1959 A.MARZO CCHIETYAL METHOD OF CLEANINGAND COATINGSIZEDGLASQFABRIC File dSept. 2, 1954 I 2 Sheets-Sheet 1 I/OLAT/LES REMOVED GLASS FAEE/C F/A/IS/l APPLIED w w S M T OM T 0 R A T A CR EM v N s I M U A Jan. 13, 1959 A. MARZOCCHI ET AL 2,868,669

METHOD OF CLEANING AND COATING SIZED GLASS FABRIC Filed Sept. 2, 1954 2 Sheets-Sheet 2 INVENTOHS ALFRED MAPZOCCH/ ReML/s-F CAFPOSELL/ GERALD E.RAMMEL ATTYS.

METHODDF CLEANING AND COATING SIZED.

, GLASS, FABRIC,

AlfredMarzocchi, Pawtucket; and Remus-F. Caroselli;

Manville, R: Ia, andGerald E. R'animel, North Attleboro,v Mass., assignors: to Owens-Corning Fiherglas Corporation, a corporation: of Delaware;

Application Septemher 2,,19 4, SerialjN0 .s453, 782

6 Claims; (Cl: 11 75-46) This invention relates to the treatment of fibrous glass andproducts thereof l and particularly to improving the physical properties of fibrous glass in the form of fabric or the like.

Inrtreating fabrics woven of fibrous glass in an attempt to:- color the glass; it has been found advantageous to heat clean the glasspriortodyeingor printing;- Certain of the fabrics such as staple fabricsand'thesoft', thick satin weaves produced either from: staple or continuous fibers. have: presented a problem when attempts have been madeto heat cleanthemusing the: conventional equipment and methods. dualj purpose: (1')? a freshv and clean-surfacewhich is highly receptive to chemical combination withtreating substances; is presented upon the fibers and strands, and ('2)-=str-ands'from which the fabr-ioiswoven becomeweaveset.

Removal of the size or' lubricanbEwliichwas: applied to: the fibrous glass in. order; to: facilitatev forming and weaving is: necessary in order to present clean glass surfaces to which the. fabric finish; can adhere. fibers maybe cleanede by- -washing; however, ita has: been foundipreferableato burnthe size, lubricant. and/ on other treating material from: thesurfaces of The; fib'ersrin; order to, clean; them. Controlling; the: heating: of the 1 fibrous I'n the drawings, Figure Liz isa side elevation of part,-

of the apparatusof the invention;

' Figure 1bis aside elevation of the remainder of the apparatus; Y

Figure 2'is an enlarged side elevation of the feed end ofthe apparatus showing the scray pan andpreheat roll; and Figure 3' is a perspective view of the preheat roll.

The apparatus comprises a let-otfstand 1'1, idler rolls 12, 12, a pair of pull rolls 13', 14', the former being driven. and the latter being an idler. adapted for movement through the horizontal plane, into and out of contact with driven pull roll 13,. The pull rolls are actuated when scray pan-.15,.is to befilled, Scraypan 15v isfilled. during lacing operationsiandt when a, splice isrtot be made between. endsof fabric as when a new roll 16vis being placed on let-offstand 11. Roll 16. when supported in let-off: stand 11'has a-leather strap brake. l lwhich, provides aconstant resistance to; unrolling I ofthefabric, see Figure 2, As ,seentin Figure 2-,, a sewing;

Heat cleaning of the fabrics-has-a The Idler roll, 14 iS.

United States PatentO 2,868,669 Patented Jan. 13,1959

2. machine 18 provided with a transverse railway. carriage is mountedon frame 19 for securing the ends; of;rolls of fabric together.

Guide ro11'2'1-is'disposedabove scray pan; 15 as are the three tensioning rolls 22,, 22 The uppermostflte'nr sioning roll is provided with a leather strap,braking member 23. After the fabric passesover expander; roll 24 where the longitudinal wrinkles, in the clothare rifl moved, it passes around preheatroll 2,5fand' thenover guide rolls 26, 27 before entering'weavesetoven 28; The weave set oven; is provided with-a plurality ofiga's, burners 29; 29, which heat the oven to the desired temperature. The, combustionproducts fromthe burners surround a stainless steel muffle 31in flieOYen-ZK and are then vented'through exhaust staekvlizf.

Stainless steel muffle '31" through which. the fabric passes is provided with air manifolds 42, 42jwhiehare adapted'for directingair or oxygen upon theupper and lower surfaces of the fabric being. heatedg see Figure, 1a Thetwo air manifolds are disposed one abovetheother and extendtransversely across the width of the rnuflle andthefabric. The air manifolds 42, 42 havea plurality of--openings which direct a stream ofjair or oxygenifa ;a angle towardthe surface of the fabric being treated and against-the direction, of' travelji ofv the fabric ashit passes through the mufilefl" of the weave set oyen'} Stainless steeLmuflie 31" is vented through exhaust stack 33-which is positioned above air manifolds 42 42jarid extends at its lower end; across the width of stainless; steel muffle 31*. At'the entrance andiexit ofthe stainlessn steel muffle and of oven'28 are. adjustable doors, 34, 3'4 and 35 35.

Above-preheat-roll 25 is an' exhaust; duct 36fadapte'd emitsr Bremixing chamber 39 is supplied with-,ai'randi' gasas indicated and the gas and; air'mixture! istthen supplied to both ends o f the inner burner. 375by; the

piping system shown. Gas Vail/(154% controlsathe flow tzr s, a d a rmmixture to. inner burner. 37: 1 Heat cleaned fabric 43 passes over guide roll 44 as it emits frQm;weave-set oven 28.

Draw roll unit 45 comprises two motor-driven rolls 46", 46 positioned 'oneabove the other and onefidlerroll 47 The draw roll; unit pulls the fabric' th'r h,

the weave s'et oven with the* proper; tension, and

feeds the fabric intopadder 48. Draw-rolLunitASfis' provided with a scraypan 49 which is' used whenthe; fabric is to-be heat cleaned only. When heat cleaning,

only; the fabric-is directed to a, roll-up unit immediately after passing over the draw roll unit 45Qandthe. scray pa-nisused'when changingrol'ls at the. rollruptunit. Driven rolls 46,46 may be rubber covered or may,

be stainlesssteelrolls.whichiare, water cooled tothelp; resist the oxidation which normally takes place because ofthe elevated temperatures to, which the drawa rollj, unit is subjected. I Padder 48. comprises a. guide roll 51, an immersiong.

roll 52 disposed within dip pan- 53; expander- -rollf 54: and a pair. of padder rolls 55, 55. The paddermollv are large diameter rubber covered rolls, therubber having a shore-r A Durorneterhardness of about 65. The lowermost padder, roll is; partially submerged in the liquor contained, in; tank .56: The uppermost padden ro1l-is :-jo1.1rnal1ed'inlever arms 57 which are pivotedat tric motor 62 and 'drive chain 63 and the upper padder is 'free to turn on its own' axis. i i

The finishing agent, which may or not include a dye as applied by padder 48, is set by passing the treated fabric 64 through drying oven 65. The drying oven is provided with a plurality of chain driven rolls 66, 66

over which the fabric passes in the required number of passes as it is being dried. After the fabric leaves the drying oven, it is directed to roll-up unit 67. Roll 68 of the take-up section 69 is driven by electric motor 71 'through drive belt 72. The spindle of roll-up stand 73 is driven by motor 74 through drive belt 75. A scray pan 70 is disposed between take-up section 69 and roll-up unit 67. Take-up section 69 runs at a constant speed and feeds the fabric to roll-up stand 73. During the time required to remove full rolls of the finished product, the fabric is deposited into scray pan 70. The speed of the roll-up stand 73 varies as the roll. size increases as this section is driven by a constant torque motor.

' Although only one padder and one drying oven are shown, for many applications another padder and oven is inserted into the line between the drying oven 65 and roll-up unit 67 shown in Figure 1b. Any number of padders or padders and ovens may be inserted as desired. Two, three or more successive padding and drying steps are sometimes used.

The production equipment as described has a central direct current (D. C.) controlled drive system for regulating the speed ofthe fabric from the draw roll unit 45 to the roll-up unit 67. Rheostats are located at the draw roll unit 45, the oven 65, the padder 48 and rollup unit 67 to control the speed of the fabric so that the tension can be finely adjusted at each unit.

' For the purposes of illustration and not intending to limit the invention thereto, a description of the treatment of a particular fabric will be described. A decorative fabric comprising fill yarns having a size thereon comprising the following ingredients in weight per cent is the starting material.

' Example I 1 Percent Ingredient: by weight Tricresyl phosphate 10.0 Ethylene oxide polymer 5.0 Alkylaryl polyether alcohol 0.5 Water 84.5

Ingredients which may be added to this forming size in addition to or as a substitute for the alkylaryl polyether alcohol are such materials as polyamines, tetraethyl pentamine, dibasic acids, a methyl ester of rosin, phenolic resins, polyvinyl methyl ether maleic anhydride, polybutenes, ethylene oxide-polyoxy propylene condensation products, titanium glycolates, titanium acylates, polyvinyl acetate, polyvinyl methylether, chlorinated alkanes, chlorinated petroleum waxes, and the like. The staple size comprises basically from 5 to 25% by weight tricresyl phosphate and from 5 to 25% ethylene oxide polymer, the remainder being water.

Other suitable sizes may be used for either or both the fill and warp yarns of the fabric; for instance, a carbon tetrachloride and kerosene mixture is entirely satisfactory as the size for the fabric to be treated. Mixtures of ethylene oxide polymer or other lubricants and water with no addition of tricresyl phosphate may be used as the size also.

The yarns from which the fabric is woven may be treated with a gelatine size such as is disclosed in U. S. Patents 2,245,620 and 2,371,933 issued to Hans Steinbach on June 17, 1941, and March 20, 1945, respectively.

Fabrics which have been successfully used are those having warp yarns treated with a size comprising gelatine andan oil and fill yarns treated with the size of Example I. p

In starting the apparatus a leader cloth constructed of fibrous glass and heavy glass cord are used. A wooden shell or tube of leader cloth is placed on let-01f stand 11 and brake 17 is released. The leader cloth is laced through the apparatus substantially following the path shown in Figures 1a and lb. Metal hooks or the like are used to pull the leader cloth through weave set oven 28. After the leader cloth is laced through draw roll unit 45, heavy glass cords which have been laced through the padder rolls 55, 55, drying oven 65, and roll-up unit 67 are securedto the leader cloth.

Once suflicient leader cloth has been taken through the charge end of the line, a roll of fabric to be treated is placed on the let-0E stand and the cloth end is attached to the end of the leader cloth by using sewing machine 18. A single stitch seam using glass sewing thread is made.

7 After the lacing has been completed, weave set oven 28 and drying oven 65 are brought to operating temperature by lighting the gas burners in each. Gas valve 41 is opened and preheat roll 25 is lighted to bring the preheat roll up to operating temperature. The preheat roll may be maintained at a temperature of from 500 to 900 F. when processing a fabric at least some of the yarnsof which have a forming size thereon such 6 as that described in Example I, a surface temperature of 600 F. is preferred. The temperature of the weave set oven 28 may be from about 900 to 1300 F. A temperature of 1200 F. is preferred when a staple yarn fabric comprising fill yarns having the size of Example I and warp yarns with gelatine size is being treated. A staple fabric comprising staple fibers treated with the size of Example I is fully heat cleaned at a temperature of about 1000 F. Drying oven 65 is maintained at a temperature of from 200 to 400 F. and preferably from 275 to 375 F. The drying oven temperature is preferably about 360 F.

The finish or after treatment solutions are prepared and introduced into dip pan 53 and adjoining tank 56.

A finish comprising the following ingredients is prepared and introduced into both dip pan 53 and tank 56.

Quaternary nitrogen compound (reaction product of an amide reacted with triethanolamine) 8 Stearato chromic chloride 2 Water 88.5

As the process continuesvmore finish is added to dip pan 53 as required to replace that being applied to the fabric. Other suitable finishes include those of U. S. Patent 2,686,737, issued August 17, 1954. Pigments and dyestuffs are added to the finish when desired.

The central drive is energized and the process is then commenced. The fabric to be treated is advanced through weave set oven 28 by the action of draw roll unit 45. As the fabric passes over preheat roll 25, volatile gases from the size on the fabric are driven ofi. The volatile gases from the tricresyl phosphate and ethylene oxide are removed through duct 36. The fabric then passes horizontally through weave set oven 28 where the size is first carbonized and then completely burned off leaving a white cloth comprising fibers having clean surfaces. When the fabric passes air manifolds 42, 42, the combustion of the size is completed. Complete combustion of the size is indicated when a blue colored flame is produced in the Weave set oven. The jets of air or oxygen from manifolds 42, 42 preferably are directed at a 45 angle toward the oncoming fabric. Complete combustion of the size materials upon the fabric will make it possible to achieve -atrue white fabric. Then if the fabric is to be dyed; true .color shades can be accomplished o1:.=if.. the fabric isto :re-

main undyed, a true white is provided.

When using the preferred temperatures, the fabric is --.advanced.at a'rate of 18 /2 feet per-minute. -Air-cylinders "59 are set so that the pressure on thejpadder rolls 55, 55

is 35 pounds per square inch. In the pa'dderunitthe fabric is drawn through dip pan 53 and then through padder rolls 55, 55 which distributes the finishing agent throughout the fabric and removes the excess finish. The excess finish is collected in tank 56 and is returned to dip pan 53 through a connecting tube. The tension of the fabric between the draw roll unit 45 and padder 48 is controlled by adjusting the speed of the padder rolls 55, 55 with a rheostat which is a part of the D. C. central drive system.

As the fabric travels through drying oven 65 moisture is removed from the finish on the fabric and the finish becomes set upon the fabric.

When treating staple fabrics and satin Weave fabrics and the like, it is necessary to use a preheat roll such as that disclosed in order to control the cleaning of the fabric in the weave set oven. The volume of volatile gases which are driven off within the weave set oven if no preheat roll is used is great enough when treating these fabrics that it is very difficult and at times impossible to control the temperatur'es attained in the weave set oven. It has been discovered that by using a preheat roll the volatiles can be driven off controllably and that the remainder of the size is then burned off with a greater degree of accuracy and complete combustion can be attained without destruction of the physical properties of the fibrous glass.

When running fabrics such as staple fabrics, the pull rolls are usually maintained open. When treating such fabrics, draw roll unit 45 pulls the fabric through the weave set oven. When the need for a new roll arises, pull roll 14 is moved into contact with pull roll 13 and pull rolls 13 and 14 are speeded up to accumulate enough fabric in the scray pan 15 to allow time for the splicing operation. When the splice has been made, pull roll 14 is again moved to the open position and driven roll 13 is stopped. When treating other fabrics such as marquisette, pull rolls 13 and 14 are maintained in a closed or in-contact position except when a splice is being made. A supply of fabric is maintained in the scray pan 15 at all times, the amount being controlled by adjusting the speed of the pull rolls 13, 14. Heavy fabrics such as casement fabrics, staple fabrics and the like are not folded in the scray pan 15 except when it is necessary to make a splice.

As stated before, more than one padder and drying oven may be used. Two padders and two drying ovens are used when applying finishes comprising butadiene acrylonitrile and stearato chromyl chloride or tetrafluoroethylene or polyethyl acrylate and colloidal silica and the like. For instance, when applying a finish comprising polyethyl acrylate and stearato chromyl chloride, the following procedure is followed.

The fabric is passed through the weave set oven which is maintained at a temperature of from 1150" F. to 1225 F. at a speed of about 20 feet per minute. The fabric passes through the first padder where an emulsion of polyethylacrylate and dye is applied and then the fabricis dried at a temperature of from 275 to 300 F. A dispersion of stearato chromyl chloride is applied at the second padder and the fabric is dried at a temperature of about 345 F.

The speed of the fabric through the apparatus may vary widely depending upon the type of fabric being treated and upon the size which has been applied to the fabric prior to its treatment in the apparatus of this invention. The speeds may vary from about 15 to about 80 feet per minute. The weave set oven temperatures vary also depending upon the speed at which the fabric is passed through the oven. If the speed of the fabric is increased,

L chamber to help. remove wrinkles from the fabric; how- :ever, the;.preheat.roll .is veryeffectiveas a device-toremovewrinkles.

*It ,is' possible using the .apparatusiof this invention to control the heat cleaning, Weave setting and subsequent application of finishes and dyes with much greater accuracy. Higher quality products are possible because of this added control. Complete cleaning allows perfectly white fabrics to be produced and, in addition, gives brighter and truer shades of color when the finish includes a dye. In addition to these advantages, certain of the heavy fabrics including the staple fabrics are now treated under'controlled conditions. The continuous twostep heating process carried out by the preheat roll and the weave set oven has provided the key to treatment of heavy bulky fabrics such as staple fabrics and the like.

Various modifications can be made within the spirit and scope of the following claims.

We claim:

1. Method of applying a finish to a fibrous glass fabric having a size thereon comprising a two-stage cleaning step and a finish application step, said two-stage cleaning step comprising advancing said fabric toward a combustion chamber, heating said fabric immediately prior to its reaching said combustion chamber to a temperature of from about 500 to 900 F. to drive off sufficient amount of the size in the form of volatile materialsto allow controlled heat cleaning of the fabric in a subsequent step but leaving sufficient amount of size thereon to allow burning of the remaining size to provide complete heat cleaning, and then heating said fabric in a combustion chamber to a temperature of from about 900 to 1300 F. while simultaneously directing a stream of a combustion supporting gas toward the surfaces of said advancing fabric to heat clean and weave set the fabric.

2. Method of cleaning fibrous glass fabric having a size thereon comprising continuously advancing the fabric toward an oven having a combustion chamber, heating said advancing fabric while it is outside the combustion chamber to a temperature at which a sufficient portion of the size in the form of volatile materials will be removed from the fabric to allow controlled heat cleaning by burning in a subsequent step, and heating the fabric within the combustion chamber to a temperature sufficient to burn completely all material-s remaining on the fabric to provide a completely cleaned fabric.

3. Method of claim 2 wherein the fabric is heated to a temperature of from about 500 to about 900 F. outside the combustion chamber.

4. Method of claim 3 wherein the fabric is heated to a temperature of from about 900 to about 1300 F. within the combustion chamber.

5. Method of heat cleaning heavy fabrics of glass having a size thereon comprising heating the fabric to remove a suflicient portion of the size in the form of volatile materials to allow controlled and complete removal of remaining portions of the size in a subsequent burning step, and heating the fabric to a temperature of from about 900 to about 1300 F. in a combustion chamber for complete heat cleaning.

6. In a process of heat cleaning fibrous glass fabric having a size thereon comprising heating the fabric in a combustion chamber to a heat cleaning temperature of from about 900 to about 1300 F., the step of heating the fabric prior to introduction into the combustion chamber to a temperature SllfilClCDt to remove a portion of the size in the form of volatile materials from the fabric so that the above heat cleaning temperature range can be maintained within the combustion chamber for complete heat cleaning by burning.

(References on following page) 8 v References-Cited in the file of this patent J 2,633,428 'Klug Mar. 31, 1953 UNITED STATES PATENTS Ffil'iel" Jan. 26, 790,050 Hall May 16, 1905 1 OTHER REFERENCES 1,863,687 Cramer June 21, 193 Coronizing Process Manual, publ. by Owens-Corning 1,940,975 Shaver Dec. 26, 1933 Fiberglas Corp., N. Y., 1948, pp. BA-l to 3; BB-l; CA-Z;

2,344,601 Collins Mar. 21, 1944 CB4 and CES. 

1. METHOD OF APPLYING A FINISH TO A FIBROUS GLASS FABRIC HAVING A SIZE THEREON COMPRISING A TWO-STAGE CLEANING STEP AND A FINISH APPLICATION STEP, SAID TWO-STAGE CLEANING STEP COMPRISING ADVANCING SAID FABRIC TOWARD A COMBUSTION CHAMBER, HEATING SAID FABRIC IMMEDIATELY PRIOR TO ITS REACHING SAID COMBUSTION CHAMBER TO A TEMPERATURE OF FROM ABOUT 500* TO 900*F. TO DRIVE OFF SUFFICIENT AMOUNT OF THE SIZE IN THE FORM OF VOLATILE MATERIALS TO ALLOW COMTROLLED HEAT CLEANING OF THE FABRIC IN A SUBSEQUENT STEP BUT LEAVING SUFFICIENT AMOUNT OF SIZE THEREON TO ALLOW BURNING, OF THE REMAINING SIZE TO PROVIDE COMPLETE HEAT CLEANING, AND THEN HEATING SAID FABRIC IN A COMBUSTION CHAMBER TO A TEMPERATURE OF FROM ABOUT 900* TO 1300*F. WHILE SIMULTANEOUSLY DIRECTING A STREAM OF A COMBUSTION SUPPORTING GAS TOWARD THE SURFACES TO SAID ADVANCING FABRIC TO HEAT CLEAN AND WEAVE SET THE FABRIC. 